Floor truss systems and methods

ABSTRACT

A flooring truss system is disclosed for carrying sub-flooring materials such as a radiant heat source. A plurality of truss members carry a deck, foam, concrete, and tubing.

RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/777,154, filed Feb. 27, 2006, entitled “Floor Truss Systems and Methods.”

BACKGROUND OF THE INVENTION

The present invention relates to a structural metal member of that is used for floor joist or roof support applications.

Most residential house framing is wooden. However, some building techniques are emerging that emphasize structural integrity. For instance, insulated concrete forms, or ICF's, are stay in place forms used to build concrete homes. Benefits of building with ICF's include energy savings, fire resistance, superior structural integrity, an ecologically sound building processes.

Metal structural members are commonly are cold formed from sheet metal by rolling, folding or pressing a metal strip into a desired cross section. A cross sectional design is chosen to create optimum load bearing characteristics, including focus on stress and strain relationships.

Because metal is more structurally predictable than wood, the cross sectional shapes of the metal truss design can be optimized for weight, stress, strain, and fire resistance, amongst other benefits.

SUMMARY OF THE INVENTION

In one embodiment of the present invention, a truss system is disclosed with top and bottom chords, end webs and center webs that span a distance between support structures, such as basement walls of a house under construction. The truss system is held on the support structures by end plates that are coupled with the top chord.

In an alternate embodiment, the present invention is a truss system comprising a pair of mirror imaged elements that are plug welded together. A series of roughly oval shapes are removed from the height face of the truss system, and stress plates couple adjacent series of truss members.

In a preferred embodiment, layers of foam and concrete overlay the top portion of the truss, and in these layers can be accessories such as concrete reinforcing bar (rebar), or water lines to create a dynamic radiant floor heating system.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a truss system of the present invention, the truss system supported by a support structure such as basement walls;

FIG. 2 is a side view of a truss system of the present invention;

FIG. 3 is a cross sectional view of the truss system of the present invention, with additional home building materials carried by said truss system;

FIG. 4 is a close up cross sectional view of a truss member carrying sub-floor material;

FIG. 5 is a top view of the truss system of the present invention;

FIG. 6 is a top view of a plurality of truss members carrying sub-floor material, with additional home building materials carried by said truss system;

FIG. 7 is a side view of an alternate embodiment of the truss system of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.

Referring now to FIG. 1, a top perspective view of truss members 10 of the present invention is shown. Truss members 10 are shown supported by a support structure, in this case, the top walls of a basement of a household during construction (shown in phantom). Truss members 10 span between two walls, and generally truss members 10 run parallel to each other spanning, for example, basement walls.

A brace 12 allows the truss spans 10 to hang in their load bearing orientation.

Referring now to FIG. 2, a side view of the truss member 10 of the present invention is shown. A brace 12 is provided for hanging the trusses 10 as described with reference to FIG. 1. End webs 20 are provided, as are top chords 25 and bottom chords 23. Void spaces 24 are created thereby, between center webs 21. The number of center webs 21 is dependent on the desired length of truss members 10.

Referring now to FIGS. 3 and 4, a side cross sectional view of the truss system 10 of the present invention is shown. In this view, additional home building materials are shown carried by the truss system 10 as will be described later.

During installation of the truss members 10 to form the truss system, the truss members 10 are initially placed spanning the support structure, as shown in FIG. 1. Next, structures 48 are laid between truss members 10. Heat tubes 42, rebar 60 and decking or wire mesh 40 is laid in place, carried by the foam 48.

Next, shoring may be provided where desired (not shown), to support foam 48, to bear the weight of concrete 46 as concrete 46 is poured atop foam 48. In this manner, concrete 46 is in contact with foam 48, providing the truss system with a seal from sound or temperature variances, which keeps the living areas above and below the truss system separate, soundproof, insect proof and fire resistant. After the concrete 46 has cured, the shoring can be removed.

Because the concrete 46 will have cured against the foam 48, and truss components 20, 16, and perhaps 25, the truss system 10 are, in effect, coupled after concrete 46 is cured. This creates an insulated concrete form in a horizontal position, with the benefits of strength, insulation and soundproofing.

Referring specifically to the truss members 10, it is seen in this view that each truss member 10 has opposing bottom chords 23 which are essentially mirror images of each other, sandwiching and coupled to end webs 20 and center webs 21. Similarly, top chords 25 sandwich and couple end webs 20 and center webs 21. End plates 12 are coupled underneath top chords 25.

Center webs 21 and end webs 20 are also formed of two pieces each. Namely, right and left members of the center webs 21 and end webs 20 are mirror images of each other, and at their tops, form flanges 16, which are roughly ninety (90) degree angle bends in the center webs 21 and end webs 20, or alternatively could be coupled to, as independent elements, center webs 21 and end webs 20.

As can be seen, top chords 25 carry a structure 48, such as high density foam, between adjacent truss members 10. The purpose of the high density foam 48 is to provide both insulative properties, as well as to support other building materials resting upon or atop the foam 48. For example, as shown in FIG. 3, a series of radiant heat tubes 42 can be carried by the foam 48. Also, rebar 60 is carried by flanges 16, as well as wire mesh 40 that is laid between adjacent flanges 16. Concrete matrix 46 binds the wire mesh 40, rebar 60 and radiant heat tubes 42, and provides a ground level surface for the floor above the trusses 10. Other elements, such as insulation, air return, and hat channel (not shown), may be present either carried by the truss system 10, within the concrete matrix 46, or in the walls adjacent the trusses 10.

Piping 42 for use in a radiant flooring system. Piping 42 is coupled, for instance, to a water source and electrical source (not shown) although the piping 40 need not carry water. These electric floor-warming systems are buried directly below the flooring surface and are then connected electrically to a GFCI protected power source. 110 Volt lines are most commonly used, but 220 Volt lines can be utilized for some larger applications.

The most common radiant technology is the Hydronic Radiant Floor, or HRF. It works like any hydronic heating system, but instead of distributing heat through a convective baseboard or wall-mounted radiator, a pump circulates hot water through tubing in the floor. Tubing can be made of polybutylene, cross-linked polyethylene, or rubber.

HRFs use lower water temperatures than hydronic baseboards. Beneath a tile floor, the water temperature can be as low as 90° F. to 105° F., while a baseboard heater requires 160° F. to 200° F. water. This makes an HRF a good match with a low-temperature heat source like an air- or ground-source heat pump, or even an active solar system.

The foam layer 48 acts as an insulator, essentially blocking heat from the heating system 42 from traveling downward, instead directing the heat into the cooler concrete 46.

Referring now to FIGS. 5 and 6, top views of a truss member or members 10 is shown, with flanges 16, top chords 25, and end plates 12 carrying the wire mesh 40, and the radiant heat tubes 42.

Referring now to FIG. 7, an alternate embodiment of the truss system 110 of the present invention is shown. In this embodiment, support 114 allows the truss spans 120 a and 120 b to hang in their load bearing orientation. Truss spans 120 a and 120 b are preferably coupled together and a preferred welding technique being plug welds 122, repeated across the spans 120 a and 120 b. Cut out sections 124 of the spans 120 a and 120 b are spaced apart as shown. In a house, it may be preferable to have end sections 119, with at least one middle section 121 in place. A stress plate 126 joins middle section 121 with end section 119.

A series of support members 116 are spaced apart atop the spans 120 a and 120 b.

The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention. 

1. A floor truss system comprising: a plurality of trusses spaced apart and extending between wall structures, said trusses comprising a bottom chord, a top chord, a first and a second end web, at least one center web, said first and second end webs coupled between said top and bottom chords, and said first, second, and end webs having flanges extending above said top chord; a support structure between adjacent trusses, said support structure carrying at least one tube, and said support structure carrying a floor layer.
 2. A floor truss system according to claim 1, said floor truss system further comprising a decking material carried by adjacent trusses.
 3. A floor truss system according to claim 1, said floor truss system further comprising reinforcement bars carried in said floor layer.
 4. A floor truss system according to claim 1, wherein said top and bottom chords are each two ply.
 5. A floor truss system according to claim 1, wherein said center web, said first and second end webs form a flange above said top chord.
 6. A floor truss system according to claim 1, said floor truss system further comprising an end plate supporting said top chord on said wall structure.
 7. A floor truss system according to claim 1, wherein said tube carries radiant heating material.
 8. A floor truss system according to claim 1, wherein radiant heating material is water. 